Composite handle

ABSTRACT

An elongated composite element includes an elongated form comprising a flexible material and having a plurality of holes or a plurality of indentations or the like established thereat, and a core material that either (a) substantially fills an interior cavity of an elongated tubular form and that protrudes at least partially through the holes established in the elongated tubular form, or (b) is disposed along and over a plurality of elongated members and is at least partially received in indentations to adhere the core material to the plurality of elongated wire members. An outer layer may substantially encase the elongated form and the core material to provide an outer surface of the composite tubular element. The elongated composite element may include strengthening elements and the polymeric core portion may be disposed along and over the plurality of strengthening elements.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the filing benefit of U.S. provisionalapplications, Ser. No. 61/302,772, filed Feb. 9, 2010, and Ser. No.61/292,301, filed Jan. 5, 2010, which are hereby incorporated herein byreference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to tubular constructions, suchas elongated handles for tools, such as for brooms or shovels or thelike.

BACKGROUND OF THE INVENTION

Elongated handles, such as for brooms or shovels or the like, aretypically made of a single material, such as wood or plastic or metal.The material is formed to the desired elongated tubular shape to formthe handle. While such handles work well for their intended uses, thereare strength concerns with molded or extruded plastic or polymerictubular handles.

SUMMARY OF THE INVENTION

The present invention provides an elongated composite tubular orcylindrical member, such as for a tool handle or the like. The compositeconstruction includes strengthening means or elements that provideenhanced strength to the elongated composite element or handle. Forexample, the composite construction may include a tubular shell orrolled element that has a plurality of holes or apertures formedtherethrough, with a flowable material, such as a molten or liquidpolymeric material or resin or foam or foaming material, established inthe shell and substantially filling the shell and filling the holes orapertures foamed through the shell to form a unitary constructioncomposite elongated member. Optionally, the strengthening means maycomprise one or more elements having indentations, such as dents orholes or the like, formed therealong, or may comprise a plurality offibers or elements that may interconnect or link during the molding orextruding process and that may be securely linked together in thecomposite element when the polymeric core material cures and hardens.Optionally, the strengthening means may comprise a plurality of layersof differing materials, such as alternating layers of paper and plasticmaterials, to provide enhanced strength of the finished composite memberor product.

According to an aspect of the present invention, a method of forming anelongated composite element comprises providing at least one elongatedmember and establishing a plurality of indentations at an outer surfaceof the elongated member. A polymeric resin is extruded along theelongated member, whereby the polymeric resin is at least partiallyreceived in the indentations to adhere the polymeric resin to theelongated member. The polymeric resin is cured to form the compositeelement whereby the cured polymeric resin limits flexing of theelongated member and the elongated composite element.

Optionally, the elongated member may comprise one or more elongatedelements or wires having a plurality of indentations (such as notches orthe like) formed at an outer surface of the elongated wire or wires.Optionally, the elongated wire may comprise at least three (such as, forexample, five or more or less) elongated wires.

Optionally, the elongated member may comprise an elongated tubularmember having an inner cavity. The extrusion of a polymeric resin maycomprise extruding a polymeric resin within the inner cavity of theelongated tubular member. The plurality of indentations may comprise aplurality of holes established (such as via a press or stamping processor the like) through a wall of the elongated tubular member. Thepolymeric resin may be extruded within the inner cavity such that someof the polymeric resin flows at least partially through the holes. Themethod may further comprise applying an outer layer over the filledelongated member.

Optionally, the polymeric resin may be substantially continuouslyextruded along the elongated member as the elongated member issubstantially continuously fed through an extruder. The method mayfurther comprise cutting the elongated member and the polymeric resin toform a plurality of elongated composite elements.

Optionally, the elongated member may comprise a solid or non-tubularmember and/or may comprise a plurality of indentations established at orin its outer surface, whereby the core material may be disposed over theelongated member and may be received in the indentations to strengthenthe elongated member and limit flexing thereof.

Optionally, an elongated composite element may comprise a plurality ofstrengthening elements and a polymeric core portion disposed along andover the strengthening elements. The polymeric core portion may be atleast partially received in and around the strengthening elements, andthe polymeric core portion limits flexing of the plurality ofstrengthening elements and the elongated composite element. Thestrengthening elements may comprise a plurality of metal strands orfibers, such as steel wool or the like. Optionally, the strengtheningelements may comprise a plurality of small elements having hooks orprotrusions protruding outwardly therefrom to join or hook to hooks orprotrusions of others of the plurality of strengthening elements toestablish a network of strengthening elements in the polymeric coreportion. Optionally, the strengthening elements may comprise metallicelements or may comprise polymeric elements having a melting temperaturethat is greater than the melting temperature of the polymeric coreportion.

Optionally, an elongated composite element may comprise a plastic orpolymeric core portion and alternating layers of a plastic or polymericmaterial and a non-plastic material, such as, for example, paper ormetal or the like. For example, an elongated composite element maycomprise a polymeric core portion with a first layer of paper around andalong the core portion and a first layer of plastic around and along thefirst paper layer, and with a second layer of paper around and along thefirst plastic layer and a second plastic layer around and along thesecond paper layer, and so on, with the alternating paper and plasticlayers being repeated a desired or selected or appropriate number oftimes to achieve the desired or selected diameter of the elongatedcomposite element and/or the desired or selected strength of theelongated composite element. The outermost polymeric layer may providethe outer surface of the finished elongated composite element, oroptionally an additional polymeric layer or coating may be applied toprovide the desired outer surface color and/or texture and/or finish forthe finished elongated composite element or product.

Therefore, the present invention provides a composite elongated member,such as an elongated handle for a tool or the like. The compositeconstruction comprises a strengthening portion or element or means, suchas a paper or metallic tubular member or members or wire member ormembers or linking elements or the like, while the polymeric coreportion is disposed within and/or around and along the strengtheningportion, whereby the interaction between the polymeric portion and thestrengthening portion results in a substantially strong and non-flexibleelongated handle or the like. The strengthening portion or element maycomprise an elongated member with holes established therethrough (suchas for a tubular strengthening portion made of paper or metal or plasticor the like) and/or indentations or notches established at a surfacethereof (such as for metallic wires or the like).

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tubular handle formed in accordancewith the present invention, shown attached to a shovel head;

FIG. 2 is a perspective view of a punch press that punches holes in arolled material during the process of forming the tubular handle of thepresent invention;

FIG. 3 is a perspective view of a roll of steel or paper or the likethat is fed into the punch press of FIG. 2;

FIG. 4 is a perspective view of a roll former that rolls the punchedmaterial to form a generally tubular shell during the process of formingthe tubular handle of the present invention;

FIG. 5 is another perspective view of a roll former, shown with anextruder that extrudes a foam or polymeric material into the rolled andpunched shell in accordance with the present invention;

FIG. 6 is a perspective view of the rolled and punched shell, shown withpart of the shell having the extruded core material therein andprotruding from the punched holes;

FIG. 7 is a perspective view of another extruder that applies an outerfinish to the formed and extruded shell and core during the process offorming the tubular handle of the present invention;

FIG. 8 is a sectional view of an elongated element or handle formed inaccordance with the present invention;

FIG. 9 is a sectional view of another elongated element or handle formedin accordance with the present invention;

FIG. 10 is a sectional view of another elongated element or handleformed in accordance with the present invention; and

FIG. 11 is a sectional view of another elongated element or handleformed in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, an elongated tubular element 10, such as elongated handles fortools, such as for brooms or shovels (FIG. 1) or such as for otherelongated structures, such as fence posts or the like, includes a shellor strengthening portion 12 and a plastic or polymeric or core portion14 established within and/or partially through and/or around the shellportion 12, as discussed below. An outer layer or finish portion 16 maybe established over the shell portion 12 and core portion 14 to providethe desired outer surface of the elongated tubular element 10, as alsodiscussed below. Optionally, the shell portion may comprise a tubularportion with the polymeric core portion disposed therewithin or theshell or strengthening portion may comprise one or more wires extendingwithin and along the polymeric core portion, whereby the core portionand the shell portion cooperate to provide enhanced strength of theelongated element while limiting flexibility of the elongated element orhandle, as also discussed below.

In the illustrated embodiment, and as shown in FIGS. 2-5, shell portion12 comprises a flexible material that may have a plurality of holes orapertures 18 formed therethrough and that may be formed to a generallytubular or cylindrical (or other tubular shape) shape. In theillustrated embodiment, the shell portion 12 is provided as a coiledsheet 20 of flexible material (FIGS. 2 and 3), such as a coiled metallicmaterial, such as steel or aluminum or the like, or a coiled papermaterial or cardboard material or the like, or a polymeric or metallicscreen or mesh material or the like (or any suitable substrate orreinforcement material), whereby the coiled sheet is uncoiled to form anelongated strip or ribbon or portion or sheet 22 for forming into thetubular shape. For example, and as shown in FIG. 2, the coiled sheet 20may be uncoiled and the uncoiled strip or ribbon 22 may be fed into apunch press or piercing device or other hole or indentation establishingmeans 24, which is operable to punch (or otherwise form or establish)holes or apertures 18 through the elongated strip 22. As shown in FIG.2, the apertures may be punched so that portions or tabs 22 a of thestrip protrude from an inner side or surface 22 b of the strip 22.Optionally, a steel substrate may be stretched to a desired length andwidth (for example, a 4 inch plate steel may be stretched to have a 2.5inch width and then may be used as the elongated strip that is punchedto have the apertures established therethrough and that may be rolled orcoiled.

As shown in FIG. 4, the punched strip 22 may be fed to a roll former 26,which is operable to roll the generally planar strip 22 into a hollowtubular form or shell portion 12, with the portions 22 a of the strip 22at the apertures 18 protruding radially inward into or partially into aninner cavity established within and along the tubular form or shellportion 12. Optionally, the strip may be otherwise formed to its tubularshape via other forming means, such as dies or other manipulating meansat the cross head of the extruder that extrudes the core material, asdiscussed below, whereby the manipulating means or dies or the like maymanipulate or form the strip to the desired shape at or in the crosshead of the extruder. Although the apertures are shown in FIG. 4 asbeing generally rectangular-shaped as the strip is fed into the rollformer and generally circular-shaped after the strip is formed to itstubular shape, this is not intended to show that the holes are modifiedby the roll former to change the shape of the holes, but rather is todemonstrate that the holes may be formed in different shapes (such ascircular or non-circular shapes) while remaining within the spirit andscope of the present invention.

During forming of the tubular form or after the strip is formed to itstubular or cylindrical shape, a core material or portion 14 (such as apolymeric or plastic resin material with a foaming agent or the like)may be established within the inner cavity of the tubular form or shellportion 12 and fills or partially fills or substantially fills the innercavity. The plastic or polymeric material or materials may comprise anysuitable material, such as, for example, low cost plastic material suchas recycled plastic bottles or the like. For example, and with referenceto FIG. 5, an extruder 28 may be disposed at or near the roll former 26and may be operable to extrude a plastic liquid or resin material intothe inner cavity of the rolled form or shell portion 12 as the strip 22is formed to its generally tubular form or shape. The resin material orcore portion 14 may foam or expand (such as while the filled shell movesalong the production line) so that the plastic material oozes or flowsthrough or fills or protrudes outwardly at least partially through theapertures 18 and may protrude outwardly beyond an outer surface 12 a ofthe tubular form or shell portion 12. For example, and with reference toFIG. 6, the tubular shell 12 may leave the roll former 26 and extruder28 with the tabs 22 a bent inward or extending inward (or the tabs maybe removed or may be otherwise not present if desired) and with the corematerial 14 substantially filling the inner cavity of the tubular shell12 and substantially encompassing or enveloping the tabs 22 a andexpanding within the tubular shell and having portions 14 a protrudingoutward through the apertures 18 of the shell portion 12. The portions14 a of the core portion 14 substantially lock or secure or retain thecore portion relative to the shell portion to limit movement of orflexing of or compression of the shell portion, thereby providing anelongated tubular element with enhanced strength over conventionalmolded or extruding plastic handles.

Optionally, the indentations or holes at or in the shell portion orsubstrate or strip that forms the shell portion may be established viaany suitable means. For example, the holes may be established bypiercing a substrate or formed strip or tubular shell and stretching thepierced substrate or strip or shell a desired or appropriate amount toform the desired length strip or shell and to stretch or open thepierced slits to establish holes through the wall or walls of thetubular shell. Optionally, for example, a shell portion suitable for usein making a composite tubular element in accordance with the presentinvention may be formed by weaving fibers or wires or the like to form awoven tubular element having a plurality of holes defined by thespacings between adjacent fibers or wires. After the core material isextruded or disposed in and along the woven fibers (with the materialflowing between the fibers and through gaps between the fibers), thecore material, after it has cured and hardened, limits or substantiallyprecludes relative movement between the individual fibers.Implementation of such piercing and/or weaving processes maysubstantially reduce the punch scrap and waste of the shell materialduring the manufacturing processes, and thus may reduce the cost of thefinished product. The woven or pierced or otherwise formed tubularelement or mesh tubular element may be filled or partially filled with acore material to construct the elongated composite element.

Optionally, it is envisioned that the tubular element may have a hollowor partially filled core portion. For example, the extruder may extrudethe core material inside the elongated tubular shell and establish ahollow core portion with a hollow cavity or passageway within and alongthe formed tubular element. Optionally, it is further envisioned thattwo or more different diameter tubular elements formed in accordancewith the present invention may be assembled together to form atelescoping tubular construction or handle assembly. For example, alarger diameter tubular element may slidably or movably or adjustablyreceive a smaller diameter tubular element therein (with an outerdiameter of the smaller element being slightly smaller or generallyequal to the inner diameter of the cavity or passageway formed along thelarger element) to provide an adjustable length handle assembly or thelike.

In order to provide a substantially smooth or uniform outer surface tothe tubular element or handle 10, an outer coating or surface portion 16is established over and around and along the tubular shell portion 12and core material 14 (including outwardly protruding portions 14 a). Forexample, and with reference to FIG. 7, a cross head extruder 30 may beprovided that extrudes or applies the outer coating or portion 16 to thecore filled shell as the shell portion passes through the extruder.Thus, the core portion 14 and filled shell portion 12 may enter thecross head extruder 30, which then applies the final finish or coatingor portion 16 to the core filled shell. The outwardly protrudingportions provide additional surfaces for the outer coating 16 to bond oradhere to as the outer coating is coated over the shell and coreportions and cures to its cured state.

The coiled flexible material may be substantially continuously uncoiledand fed to the punch press, which punches holes as the material or stripis fed through. The punched strip may be substantially continuously fedto the roll former and extruder (such as at a rate of, for example, 1foot per second or faster or slower depending on the particularapplication), whereby the strip is formed to its tubular shape and thecore material is extruded therein in a substantially continuous manner.Likewise, the filled tubular form may be substantially continuously fedto the extruder that applies the outer portion to cover the filledtubular form in a substantially continuous manner (which may be appliedor extruded while the core material is oozing out through the aperturesin the tubular member). A plurality of handles or elements may then becut at the end of the production process to establish the desired lengthhandles (or other forms) while the materials are fed and punched andextruded in a substantially continuous manner.

The composite element or handle may be formed via any suitable formingprocess. For example, a method of forming an elongated composite elementmay include providing a sheet or ribbon or coil of flexible material(such as metal, paper or any suitable flexible substrate orreinforcement material that may be coiled or otherwise provided forfeeding into an extruding device or the like). The method may includeestablishing a plurality of holes (such as via punching or stamping orpiercing or otherwise forming holes or indentations, where tabs ofmaterial of the flexible sheet may protrude at the holes) in and along asheet of flexible material and forming the sheet of flexible materialinto an elongated tubular form (such as via a roll former or dies or thelike that bend or shape the strip or ribbon into an elongated tubularform. The elongated tubular form is at least partially or substantiallyfilled (such as via extrusion) with a core material (such as a polymericresin or the like that is flowable or liquid in its uncured state) thatat least partially or substantially fills an interior cavity of theelongated tubular form and that protrudes at least partially through theholes established in the elongated tubular form. The core material maycomprise a polymeric core material with a foaming agent so that thepolymeric material expands during and after extrusion to flow into andat least partially through the holes so that a portion of the corematerial may protrude outward from the outer surface of the elongatedtubular form. Optionally, an outer portion may be formed over and aroundthe elongated tubular form and the core material to establish an outerlayer of the composite element. The outer portion may be extruded overand around the elongated tubular form and the core material.

Thus, the present invention provides an elongated handle and method ofmaking an elongated handle that comprises a plastic reinforced handle.The plastic or polymeric filler or core portion is established at andwithin a substantially non-compressible substrate or shell portion (suchas a paper or cardboard or metal shell or the like). Such an elongatedelement provides enhanced strength and can be manufactured at reducedcosts compared to conventional plastic or metal handles. The shell maybe formed to a tubular shape via any forming means and may be fed to afilling device (such as an extruder or the like) that fills the shellwith the polymeric resin of the core portion, and the filled shell maythen be fed into another extruder or device that applies an outerportion or coating over the filled shell, and the outer portion may beapplied while the core material still oozes or foams or expands throughthe apertures of the shell portion. Such a reinforced plastic handle (orother elongated element) may be manufactured as a continuous orgenerally continuous element that may be cut to the desired lengths atthe end of the process after the outer portion is established over thefilled shell.

Optionally, a reinforced elongated tubular element may be formed with apolymeric resin established at and along a plurality of wires or strandsof wire or cables, where the wires may be disposed within the shellportion or may replace the shell portion and provide enhanced strengthand reduced flexibility of the elongated element. For example, aplurality of wire strands (such as five or more or less) may be uncoiledfrom respective coils and may be fed into an extruder or other moldingor extruding device. The extruder extrudes the plastic or polymericresin around the wire strands with the wire strands extending generallyalong and within the extruded element (such as generally along a centerportion of the extruded element). Optionally, and desirably, and asshown in FIG. 8, the wire strand or strands 114 of a composite elementor handle 110 may be notched or roughened or otherwise processed so thattheir outer surfaces have a plurality of indentations or notches orrecesses 114 a or the like established thereat, whereby the polymericresin 112, when established around the wire strands (only one shown inFIG. 8, but the element or member could have two or more strandsextending therein and therealong), fills or substantially fills thenotches to further secure or attach or adhere or bond the shell materialto the strands, thereby limiting or substantially reducing theflexibility of the wire strands and the flexibility of the finishedelongated element. In such an application, the shell portion may providethe desired outer surface and the additional process of applying anouter coating may be obviated. Thus, multiple spools of wire or cable(such as steel wire or other metallic wire or the like) may be uncoiledand processed to establish the indentations or notches (such as via anysuitable notching means) and fed into an extruder, and the plastic resinmaterial may be extruded over and around the wires (which may first beprocessed to establish notches or the like at their outer surfaces) asthe wires are fed through the extruder in a generally continuous manner,whereby the elongated composite element may be cut to the desired lengthafter the extruding process and before or after the polymeric resinmaterial cures to its fully cured state. The wires may be arrangedgenerally parallel to one another along the elongated element or thewires may be wound or twisted together along the elongated element,while remaining within the spirit and scope of the present invention.

Optionally, it is envisioned that the strengthening material maycomprise any suitable strands of fibers or metal or the like and thatthe strands or fibers may be any suitable shape. For example, and asshown in FIG. 10, the strengthening material 114′ may comprise steelwool or the like that is formed in a desired elongated shape or form(such as an elongated cylindrical form or the like). The polymeric resinmaterial 112′ may be extruded along the elongated steel wool form andmay penetrate or impregnate the steel wool form to establish or form anelongated polymeric tubular form 110′ with a plurality of close knit orintertwined metallic strands or fibers 114′ disposed therein. Thepolymeric resin material 112′, when in its liquid state, may readilyimpregnate the steel wool form to fill in the elongated shape, while thesteel wool fibers provide enhanced strength and reduced flexing of theelongated shape after the polymeric material cures or hardens.Optionally, an outer polymeric coating material (or other suitablecoating material) may be applied over and along the outer surface of thepolymeric/steel wool elongated form to provide a smooth or desiredexterior surface finish to the completed product.

Optionally, other means for strengthening an elongated polymeric formmay be implemented while remaining within the spirit and scope of thepresent invention. For example, and with reference to FIG. 10, anelongated composite element or structure 210 may include a central coreportion or material 212 (which may be a solid construction or may behollowed construction or the like) with multiple layers of materialsdisposed around and along the core portion 212. In the illustratedembodiment, the elongated composite element 210 includes a firstoverlayer 214 a (such as a first layer of paper or the like) disposed orwrapped around and along the core portion 212, a second overlayer 214 b(such as a first plastic or polymeric layer or the like) disposed orestablished or extruded around and along the first overlayer 214 a, athird overlayer 214 c (such as a second layer of paper or the like)disposed or wrapped around and along the second overlayer 214 c, and afourth overlayer 214 d (such as a second plastic or polymeric layer orthe like) disposed or established or extruded around and along the thirdoverlayer 214 c. The composite element thus may have alternating layers(such as layers of paper and plastic or the like) disposed orestablished along and around the core portion to provide enhancedstrength to the composite element. The outermost layer (such as fourthoverlayer 214 d in FIG. 10) may provide the outer surface of thefinished composite element or structure or product, or a final outerfinish surface layer may be disposed over and along the outer overlayerto provide the desired or selected outer surface finish and/or textureand/or color or the like to the finished product or element.

Optionally, other strengthening means or elements may be disposed in anelongated polymeric form while remaining within the spirit and scope ofthe present invention. For example, and as shown in FIG. 11, anelongated composite form 310 may include a polymeric core portion 312that has a plurality of strengthening elements or material 314 disposedtherein. The strengthening material or elements 314 may comprise aplurality of small metallic or plastic elements that have hooks orprotrusions that function to hook together with the hooks or protrusionsof other ones of the metallic or plastic elements to establish a mesh ornetwork of connected elements disposed within a liquid polymeric resin.The elements may comprise small or micro-sized elements comprising ametallic material or a plastic material (such as a plastic material,such as an acrylic material or the like, that has a higher temperaturemelting point than that of the liquid polymeric resin in which theelements are disposed) with a plurality of micro-hooks or protrusionsprotruding outwardly therefrom. The hooks are configured to hooktogether with hooks of other elements when the elements are disposed ina liquid polymeric resin (and where the resin and elements may be mixedprior to extruding or injecting the resin into the forming means). Theelements may be generally flat elements with hooks or protrusionsextending radially outwardly therefrom in generally the same plane, orthe elements may be more three-dimensional (such as spherical or thelike) and may hooks or protrusions extending in multiple directionstherefrom and in multiple planes The resin material (with the elementsdisposed therein) may be extruded to form the desired elongated shape(or may be injection molded into a mold cavity to form a desired shape)and then cured and hardened. Thus, when the micro-elements are mixed inor disposed in a liquid polymeric resin, the elements may join togetherto form a network or mesh of metallic or plastic elements thatmechanically strengthen the polymeric material when the polymeric resinmaterial cures and hardens. Optionally, an outer polymeric coatingmaterial 316 (or other suitable coating material) may be applied overand along the outer surface of the polymeric/joined elements elongatedform to provide a smooth or desired exterior surface finish to thecompleted product.

Therefore, the present invention provides an elongated composite elementor structure, such as for use as a handle for a shovel or rake or broomor other tool or the like, with enhanced strengthening elements orconstruction or means. The composite element or structure may have aplastic or polymeric core portion disposed or extruded at or along orover or in one or more elongated members, such as one or more wires or atubular member, with the wires or tubular member having a plurality ofindentations or holes established there at or therethrough. Optionally,the strengthening means may comprise multiple layers of paper and/orplastic formed or established along and around a core portion, or thestrengthening means may comprise multiple elements disposed in themolded or extruded core portion (such as multiple strands or fibers ormultiple hooked elements that join together or link while the coreportion is in a liquid state and are retained together when the coreportion cures).

Changes and modifications in the specifically described embodiments maybe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims as interpreted according to the principles of patentlaw.

1. A method of forming an elongated composite element, said methodcomprising: providing at least one elongated member; establishing aplurality of indentations at an outer surface of said at least oneelongated member; disposing a polymeric resin along said at least oneelongated member, whereby said polymeric resin is at least partiallyreceived in said indentations to adhere said polymeric resin to said atleast one elongated member; and curing said polymeric resin to form saidcomposite element whereby said cured polymeric resin limits flexing ofsaid at least one elongated member and said elongated composite element.2. The method of claim 1, wherein providing at least one elongatedmember comprises providing at least one elongated wire member.
 3. Themethod of claim 2, wherein providing at least one elongated wire membercomprises providing at least three elongated wire members.
 4. The methodof claim 3, wherein providing at least three elongated wire membercomprises uncoiling a plurality of wires from respective spools of wiresand feeding the uncoiled wires to an extruder that extrudes saidpolymeric resin along said wires in a substantially continuous manner.5. The method of claim 4, further comprising cutting said compositeelement to a desired length.
 6. The method of claim 1, wherein providingat least one elongated member comprises providing an elongated tubularmember having an inner cavity, and wherein disposing a polymeric resincomprises extruding a polymeric resin within said inner cavity of saidelongated tubular member.
 7. The method of claim 6, wherein establishinga plurality of indentations comprises establishing a plurality of holesthrough a wall of said elongated tubular member.
 8. The method of claim7, wherein extruding a polymeric resin comprises extruding a polymericresin within said inner cavity such that some of said polymeric resinflows at least partially through said holes.
 9. The method of claim 8further comprising applying an outer layer over said filled elongatedmember.
 10. The method of claim 1, wherein disposing a polymeric resincomprises substantially continuously extruding a polymeric resin alongsaid at least one elongated member as said at least one elongated memberis substantially continuously fed through an extruder, and wherein saidmethod further comprises cutting said at least one elongated member andsaid polymeric resin to form a plurality of elongated compositeelements.
 11. The method of claim 1, wherein providing at least oneelongated member comprises: providing a flexible material; establishinga plurality of holes in a sheet of said flexible material; and formingsaid sheet of flexible material into an elongated tubular form.
 12. Themethod of claim 11, wherein disposing a polymeric resin comprises atleast partially filling said elongated tubular form with a core materialthat at least partially fills an interior cavity of said elongatedtubular form and that protrudes at least partially through said holesestablished in said elongated tubular form.
 13. The method of claim 12,further comprising applying an outer portion over and around saidelongated tubular form and said core material to establish an outerlayer of said composite tubular element.
 14. The method of claim 13,wherein applying an outer portion comprises extruding an outer portionover and around said elongated tubular form and said core material. 15.The method of claim 11 further comprising providing a roll of saidflexible material and feeding said flexible material into a device toestablish said plurality of holes in said sheet of flexible material.16. The method of claim 11, wherein establishing said plurality of holescomprises punching holes in said sheet of flexible material and whereina portion of said flexible material at said holes protrudes into saidinterior cavity of said elongated tubular form when said flexiblematerial is formed into said elongated tubular form.
 17. The method ofclaim 11, wherein said flexible material comprises a metallic material.18. The method of claim 11, wherein said flexible material comprises apaper material.
 19. The method of claim 18, wherein said core materialcomprises a polymeric core material with a foaming agent.
 20. The methodof claim 11, wherein filling said elongated tubular form comprisesextruding a core material into said elongated tubular form.
 21. Themethod of claim 11, wherein at least partially filling said elongatedtubular form comprises partially filling said elongated tubular formwith a core material that partially fills an interior cavity of saidelongated tubular form and establishes a hollow cavity or passagewayalong and within the core portion established by said core material. 22.The method of claim 11, wherein providing a flexible material andestablishing a plurality of holes in a sheet of said flexible materialand forming said sheet of flexible material into an elongated tubularform are accomplished by weaving a plurality of fibers or wires togetherto form a woven elongated tubular form.
 23. An elongated compositeelement comprising: an elongated member having a plurality ofindentations established therealong; a core material disposed along saidat least one elongated member, whereby said core material is at leastpartially received in said indentations to adhere said core material tosaid at least one elongated member; and an outer layer thatsubstantially encases said elongated member and said core material toprovide an outer surface of said composite tubular element.
 24. Theelongated composite element of claim 23, wherein said elongated membercomprises an elongated tubular form comprising a flexible material, andwherein said indentions comprise a plurality of holes establishedthrough the wall of said elongated tubular form, and wherein said corematerial substantially fills an interior cavity of said elongatedtubular form and said core material protrudes at least partially throughsaid holes established in said elongated tubular form.
 25. The elongatedcomposite element of claim 24, wherein a portion of said flexiblematerial at said holes protrudes into said interior cavity of saidelongated tubular form when said flexible material is formed into saidelongated tubular form.
 26. The elongated composite element of claim 24,wherein said flexible material comprises one of (a) a metallic materialand (b) a paper material.
 27. The elongated composite element of claim24, wherein said flexible material comprises a paper material andwherein said core material comprises a polymeric core material having afoaming agent.
 28. The elongated composite element of claim 24, whereinsaid composite tubular element comprises an elongated handle for a tool.29. The elongated composite element of claim 23, wherein said elongatedmember comprises a plurality of elongated wire members having aplurality of indentations at an outer surface of said plurality ofelongated wire members, and wherein said core material is disposed alongand over said plurality of elongated wire members, whereby said corematerial is at least partially received in said indentations to adheresaid core material to said plurality of elongated wire members, andwherein said core material limits flexing of said plurality of elongatedwire members and said elongated composite element.
 30. The elongatedcomposite element of claim 29, wherein said plurality of elongated wiremembers comprises at least three elongated wires.
 31. The elongatedcomposite element of claim 23, wherein said core material comprises apolymeric core material that is extruded along said elongated member.32. An elongated composite element comprising: a plurality ofstrengthening elements; a polymeric core portion disposed along and oversaid plurality of strengthening elements, whereby said polymeric coreportion is at least partially received in and around said strengtheningelements; and wherein said polymeric core portion limits flexing of saidplurality of strengthening elements and said elongated compositeelement.
 33. The elongated composite element of claim 32, wherein saidstrengthening elements comprise a plurality of metal strands or fibers.34. The elongated composite element of claim 33, wherein saidstrengthening elements comprise a steel wool material.
 35. The elongatedcomposite element of claim 34, wherein said strengthening elementscomprise a plurality of elements having hooks or protrusions protrudingoutwardly therefrom to join or hook to hooks or protrusions of other ofsaid plurality of strengthening elements to establish a network of saidstrengthening elements in said polymeric core portion.
 36. The elongatedcomposite element of claim 35, wherein said strengthening elementscomprise metallic elements.
 37. The elongated composite element of claim35, wherein said strengthening elements comprise polymeric elementshaving a melting temperature that is greater than the meltingtemperature of said polymeric core portion.
 38. The elongated compositeelement of claim 37, wherein said polymeric core portion, when in aliquid form is mixed with said strengthening elements, and wherein saidmixed resin is extruded to form the desired form of said elongatedcomposite element.
 39. The elongated composite element of claim 32,wherein an outer layer is applied over and substantially encases saidpolymeric core portion to provide an outer surface of said elongatedcomposite element.
 40. The elongated composite element of claim 32,wherein said strengthening elements comprise alternating layers of apaper layer and a polymeric layer disposed around said polymeric coreportion.
 41. The elongated composite element of claim 40, wherein saidalternating layers comprise a first paper layer disposed around saidpolymeric core portion, a first polymeric layer disposed around saidfirst paper layer, a second paper layer disposed around said firstpolymeric layer, and a second polymeric layer disposed around saidsecond paper layer.
 42. The elongated composite element of claim 41,wherein said second polymeric layer comprises an outer polymeric layerthat provides an outer surface of said elongated composite element.